Sappi Gratkorn increases efficiency with Experion
April 2016
PLCs, DCSs & Controllers
Paper has been produced at Gratkorn (Austria) for more than four centuries. Sappi totally revolutionised the mill by building the largest and most advanced coated fine paper production line in the world. Gratkorn has an annual capacity of one million tons of triple-coated fine paper on just two paper machines and 250 000 tons of totally chlorine free (TCF) chemical pulp. After extension of Gratkorn’s sheeting plant, it now has an annual sheet finishing capacity of 860 000 tons.
Coated papers from Gratkorn Mill are used mainly in high gloss advertising for brochures and leaflets as well as for art catalogues, books, magazines, annual reports, calendars etc.
These papers are the preferred choice where highest print quality and outstanding colour reproduction is needed and where best results are expected in die cutting, embossing, dispersion, UV-varnishing or laminating.
The challenge
The main reason for this project was quality improvements and reduction of off-spec production. In addition, plant management needed to improve operator effectiveness with a modernised automation platform and still while continuing to communicate with other legacy Honeywell products in the same production line.
The migration of the legacy Honeywell DCS, with over 12 000 I/O points, had to be completed in a very short time frame in order to minimise shutdown time and support functions for further rebuilds.
Solution
As legacy DCS and QCS systems become more difficult and costly to support, Honeywell’s Experion Upgrades enable a step-by-step transition for the most critical components. The upgrade options allow users to take advantage of the latest technological innovations in a simple, cost-effective manner.
Selected capabilities for Sappi Gratkorn include:
• Experion MX.
• Experion with PMD controller.
• Uniformance PHD.
• Safety Manager.
The site’s MXOpen QCS systems migrated to Experion MX and the TP Alcont DCS to Experion PKS. PMD and PHD are upgraded to the latest versions. Also, with Safety Manager, the site will have a fully integrated solution based on the Experion platform for its Paper Machine 11.
Benefits
Upgrading Sappi’s systems will increase process visibility and provide better operator efficiency, leading to higher product quality at lower production cost.
Experion PMD and MX provide the full advantages of a single automation platform for Paper Machine 11 with less hardware, cost savings on spares, and reduced maintenance services.
The new Experion platform delivers tools and diagnostic functions for comprehensive remote support.
Results
Using the Honeywell TPA-PMD Migration tools, it was possible to upgrade all applications and displays 100% error-free, resulting in immense time savings.
The large legacy DCS application migration at PM11 was accomplished in just three days.
Sappi reports that the Gratkorn DCS and QCS upgrade investment has achieved the scheduled targets in time and within planned production capacity.
For more information contact Boni Magudulela, Honeywell Southern Africa, +27 (0)11 695 8000, [email protected], www.honeywellprocess.com
Further reading:
ABB updates distributed control system
ABB South Africa
PLCs, DCSs & Controllers
Leveraging 30 years of continuous innovation and reliability, ABB’s updated Freelance 2024 distributed control system (DCS) offers greater plant adaptability, faster and more reliable device communication, improved system security, and seamless data exchange.
Read more...
Four ways modern operations control can boost sustainability and efficiency
PLCs, DCSs & Controllers
With the growing importance of digital transformation, HMIs and scada have evolved from control panels to vast operational hubs. Next-gen HMI/scada can bring together data, personalisation, and advanced insights to successfully achieve organisational goals, it is important to think about HMI/scada holistically within the operations ecosystem.
Read more...
The convergence of intelligence: DCS, SCADA and TLC
Schneider Electric South Africa
PLCs, DCSs & Controllers
In the early days of industrialisation, control systems were primarily mechanical, and relied on manual intervention and simple feedback loops to manage processes. Now, in the 21st century, industrial process automation systems are mind-blowingly intelligent, and provide almost unparalleled control and monitoring capabilities, making them integral to modern industrial systems.
Read more...
PC-based control for advanced hydrogen storage technology
Beckhoff Automation
Editor's Choice PLCs, DCSs & Controllers
The proportion of renewable energies from solar, wind and water is rising continuously. However, sufficient storage options are of the essence to use these energies as efficiently as possible. GKN Hydrogen offers a particularly compact and safe option, low-pressure metal hydride hydrogen storage systems with PC-based control from Beckhoff.
Read more...
ABB modernises key board mill
ABB South Africa
PLCs, DCSs & Controllers
ABB has secured a landmark contract to modernise Smurfit Kappa’s Paper Machine 5 at its corrugated cardboard mill near Mexico City. ABB will provide Smurfit Kappa with DCS, accompanied by a comprehensive paper machine drives system, encompassing some of the market’s most advanced drives and motors meticulously designed to optimise PM5’s performance.
Read more...
The synapses of the distributed control system
Schneider Electric South Africa
PLCs, DCSs & Controllers
Industrial operations require a distributed control system (DCS) to coordinate and control their process subsystems in real time. Like the brain, a DCS is a multitasking maestro, controlling and coordinating complex processes in a myriad of industrial setting such as large manufacturing plants, providing valuable top-down control.
Read more...
Modular assembly platform for clean manufacturing
Beckhoff Automation
PLCs, DCSs & Controllers
JR Automation delivers custom automated solutions for numerous industries. It has done this through its scalable, modular automation platform, FlexChassis, which speeds up time to market while cutting costs. The company chose the XTS linear transport system from Beckhoff because of its speed, and modular design that allows for multiple configurations.
Read more...
Selecting the best remote access solution for your application
PLCs, DCSs & Controllers
In today’s Internet of Things (IoT) world, remote mobile access is a necessity for many industrial applications. There are several ways of implementing this connectivity with routers and virtual private networks.
Read more...
PLCs and PACs simplify data acquisition
PLCs, DCSs & Controllers
Data acquisition, data logging and data analysis are required functions for most modern industrial control systems. The simplest and lowest cost way to provide these functions is often by using the same platform providing real-time control, namely the PLC or the PAC.
Read more...
Small-scale custom development in the information age
H3iSquared
PLCs, DCSs & Controllers
In the twenty-first century, the ability to put together custom electronic devices has become much more accessible to smaller companies, and even the private user. With the open nature of these platforms, potential developers can start learning systems easily, and do not need a massive capital output to do so.
Read more...
printer friendly version